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  1. Join Date
    Oct 2010
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    877
    #11
    4-door sedans were equipped with double retractable ELR (emergency locking retractor) seatbelts that are easy to fasten. Other models came standard with ELR seatbelts with a tension reducer to reduce the tightness and constriction on the passengers.

    Other safety measures incorporated for the fourth generation include permeation type instrument panel illumination for superior visibility, larger windshield and fender mirrors for good visual range and impact absorbing urethane bumpers.


    Other Technologies and Equipment
    Half shut door warning light for passenger safety
    Fuel gauge with hold function so fuel level could be seen with ignition OFF
    Automatic air conditioning to provide a comfortable interior environment
    Fuel lid opener inside the cabin
    Square halogen headlamps with superior illumination performance
    Power mirrors with single control lever
    Quartz digital clock


    The front wheel-drive Corolla.
    "A spacious interior in a compact sedan. Clearing the hurdles to meet world standards."

    The fifth generation Corolla was introduced on the market in May 1983, two months after the production total of Corollas reached the 10 million vehicles mark. Japan at that time was seeking a richer lifestyle, and preferences for high grade products were born. Individuals, particularly the younger generation, were exploring their own unique lifestyles, and their sense of values was diversifying. Providing an answer to this trend was the main issue for the fifth generation Corolla. The key development themes for the new model were "follow the worldwide trend of technical innovations and convert the Corolla into a front wheel drive passenger car," and "pursue ample room and styling favored by the younger generation."

    The list of appealing features and new technology incorporated in the new model could go on and on. Examples include a gracefully curved silhouette emphasizing the trends of the new era, a sleek aerodynamic body, a choice of drivetrains — front wheel drive for spacious interior and seating comfort or rear wheel drive for driving excitement and a sporty feel — a high performance engine with power and response and a fine-tuned suspension and power train.

    The fifth generation Corolla was developed to further strengthen the dominance of the Corolla as the bestselling car in the world. In the four years after its release, the fifth generation Corolla successfully acquired the No. 1 position in domestic sales and also received favorable reputations overseas.

    In March 1979, Fumio Agetsuma, who had served as Development leader of the previous generation, set forth policy to design the fifth generation Corolla as an FF (front engine, front wheel drive) model. The world at that time was beginning to show signs of FF-based passenger cars becoming the mainstream; and in 1978 Toyota released its first FF model. However, the idea of converting the Corolla to an FF design was not readily approved. Because the Corolla was a passenger car produced in record numbers, was loved by a wide range of users regardless of age or gender and was being exported throughout the world, extreme caution was taken before making drastic changes.

    In the first part of 1980 after the switch to an FF design had been approved, Agetsuma focused on the positioning of the fifth generation Corolla and stressed the need to "strive to ensure its status as a worldwide strategic vehicle that is a high quality, high grade family car and to reinforce its international competitive strength." He also declared that this Corolla "should be an innovative vehicle that incorporates new breakthroughs in every area," and thus launched the development policy for the new model.

    Concerning the FF vehicle, Agetsuma stated at that time, "I believed that competitive family cars both from Japan and overseas would soon move towards FF designs to pursue the merits of straight line stability at high speeds, handling performance and a spacious interior." Two hurdles stood before Agetsuma, who advocated an FF design for the Corolla from this belief.

    The first hurdle was a technical problem. FF designs use a complex mechanism to transmit drive power to the road surface while steering with the front wheels. Because of this complex mechanism, apprehensions existed concerning durability and repair serviceability after miles of use on rough roads. The Corolla was being exported to many nations with poor road conditions and would be driven continuously for long periods of time on bad roads. In fact, around this time there was a European manufacturer that had catastrophic results in exporting FF vehicles to nations with poor road conditions.

    The second hurdle was that of cost. In 1979, preliminary calculations showed that the investment needed to convert the FR (front engine, rear wheel drive) Corolla plant, producing 727,000 units per year, into a FF Corolla plant would total 120 billion yen. This problem was solved with engineering technology that had made significant progress, and by producing the Corolla in both the FF and FR drivetrains. By adopting the FF design for the sedan, which stressed seating comfort, and the FR design for the coupe, which stressed driving excitement, and by using existing equipment as much as possible, the team successfully reduced the equipment investment expense by almost half. In addition, to those within the company who were opposed to the switch to an FF design, Agetsuma enthusiastically explained the value demanded by the times and the importance of the FF design. Finally in November 1979, the decision to convert to FF was official.Computers were widely used to engineer the engine and design of the fifth generation Corolla, and numerous world-first mechanisms were adopted in the newly developed engine. In addition, a truly innovative vehicle was developed with more than 500 patent and utility model applications made during developments. On the other hand, Agetsuma stated the following concerning developments at that time: "The Corolla has a continuous responsibility of being the 'bread and butter' for various people in nations throughout the world. We placed emphasis on the basic areas that have the greatest impact on passengers even though those areas may be low-key. For example, we used sound proofing and vibration proofing technology and achieved an incredible level of quietness. Even when we drove the vehicle at 170km/h on the Autobahn in Germany, it provided a comfortable, secure feeling." He also stated, "When Ove Andersson, a professional rally car driver, and other European specialists praised the vehicle for being a step above European vehicles in the same class, it was more wonderful than someone praising my own son." This fifth generation Corolla was created for the world market in May 1983.

    The fifth generation Corolla entered the market with five body types, including the 4-door and 5-door (the former liftback) models in the sedan series, the 2-door and 3-door models in the coupe series and the wagon. Later in October 1984, 3-door and 5-door model hatchbacks that focused on overseas strategy were added to the lineup. Furthermore, sales of the fourth generation wagon and van models continued without any model changes, and as a result, a total of nine body types were available during that time.

    Gasoline engine variations for the sedan series included the newly adopted 1.3-liter OHC (Over Head Camshaft) 2A-LU engine, the transversely mounted 1.5-liter OHC 3A-LU engine converted from the former 3A-U, and the newly developed 1.6-liter OHC 4A-ELU engine with an EFI system. The 1.8-liter 1C-L diesel engine, which switched the former 1C engine to a transverse mount, was also available.

    In addition to offering the 1.5-liter OHC 3A-U II engine from the previous model for use in coupe models, which emphasized a sporty drive, the newly developed 1.6-liter DOHC (Double Over Head Camshaft) 16-valve 4A-GEU engine was also made available.

    In October 1984, the 4A-GELU engine, the L indicating that it was a converted version of the 4A-GEU to be mounted transversely, was offered in the sedan series and hatchback (Corolla FX). Also, in May 1985 in the latter half of the model period, the 2A-LU engine was replaced by the newly developed 1.3-liter OHC 2E-LU engine.

  2. Join Date
    Oct 2010
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    877
    #12
    The fifth generation Corolla adopted the FF drivetrain in the sedan and hatchback models, and the FR drivetrain in the other models. To better emphasize a sporty image, all coupe models, which continued to use the FR drivetrain, were unified with the vehicle name "Corolla Levin" regardless of the type of engine used.

    The design concept adopted for the fifth generation Corolla was "Let's return to the first generation Corolla." The essence of this design concept was to create original style for the fifth generation with technological innovations, such as conversion to FF, while achieving innovation like that of the first generation model. The major policy at the startup of design was to fully utilize the merits of the FF drivetrain, create as spacious an interior as possible and adopt a style directed at the younger generation. The exterior, which was designed with awareness of the younger generation, featured a large slanted nose and rounded wedge shape that emphasized surface beauty. Concerning this style, Agetsuma stated, "I think that the gently curved silhouette will create a new trend in world car designs."
    Concerning the interior, the development staff at that time stated, "We returned to ground zero and strove to create space for five adults." Specifically, the interior was expanded to the maximum limit through methods such as moving the steering wheel forward 5.5 centimeters, lowering the floor surface and adopting a more vertical angle for the rear window. In this class, designers typically agonized over making millimeter increments, so this move to expand the space by several centimeters was truly revolutionary.

    Looking at the exterior design by body type, the sedan adopted a clean, notchback style and expressed an airy image and ease of use. The 5-door model focused on aerodynamic characteristics and targeted a style that appeals to the younger generation as a vehicle featuring innovative style and function. While the coupe model was based on a design theme similar to that of the sedan series, it adopted a design with a carefree form typical of an FR vehicle, with the back end of the rear hatch pinched like a spoiler on the 3-door models.

    Three types of engines were used in the sedan series, including the 1.3-liter 2A-LU and 1.5-liter 3A-LU developed based on the 3A-U from the fourth generation and the 1.6-liter 4A-ELU. The 2A-LU and 3A-LU engines strove to improve fuel economy and power performance by adopting the world's first SCV*1 to adjust combustion efficiency at medium and low speeds, a manifold converter, and the IIA*2. As a result, the 2A-LU engine achieved a maximum output of 74ps/6000rpm and a maximum torque of 10.9kg-m/3600rpm, and the 3A-LU engine achieved a maximum output of 83ps/5600rpm and a maximum torque of 12.0kg-m/3600rpm.

    The 4A-ELU engine had increased engine displacement, EFI and TCCS*3, while inheriting the compact, lightweight, good fuel economy, and low noise characteristics of the base 3A-U engine. This high performance engine generated a maximum output of 100ps/5600rpm and a maximum torque of 14.0kg-m/rpm



    The 1.8-liter 1C diesel engine introduced in the final model period of the fourth generation was converted to a transverse mount and was offered on the fifth generation Corolla as the 1C-L. To make compatible to the FF drivetrain, the flywheel was made lighter, and changes were made to the auxiliary equipment. However, there were no changes in performance, and a maximum output of 65ps/4500rpm and a maximum torque of 11.5kg-m/3000 rpm were generated.


    On the other hand, the engines for the coupe series included the 1.5-liter 3A-U II continued from the fourth generation and the 1.6-liter 16-valve 4A-GEU. The 3A-U II engine strove for improvements in fuel economy and power performance by adopting a dual exhaust manifold and the IIA. The 4A-GEU engine, also based on the 3A-U, replaced the famed 2T-GEU. The 4A-GEU, initially developed as a single cam, 2 valves per cylinder engine, was converted into a double-overhead cam, 4-valve design after approximately a year and a half into development. This was done in favor of the higher output in the high speed range, increased combustion efficiency and intake/exhaust efficiency that the new design offered. Along with this new generation DOHC design, the engine incorporated the latest technologies, including an aluminum alloy cylinder head, forged crankshaft, Toyota-Variable Induction System and higher compression ratio. As a result, a truly high power engine with high response was achieved that generated a maximum output of 130ps/6600rpm and a maximum torque of 15.2kg-m/5200rpm. The engine was given the name LASRE*4 like the other new generation Toyota engines, and was called the LASREα 4A-GEU engine.

    In October 1984, the 4A-GELU engine, which was a converted version of the 4A-GEU engine for use in a FF drivetrain, was loaded in the sedan series and hatchback (Corolla FX). Then in May 1985 in the latter half of the model period, the 2A-LU was replaced by the newly developed 1.3-liter OHC 2E-LU engine. This engine adopted SCV, cross flow type intake and exhaust ports, a 3-valve method and a variable venturi carburetor to achieve good fuel economy and high power — with a maximum output of 81ps/6000rpm and a maximum torque of 11.0kg-m/4400rpm. Furthermore, a Partial Lean System was adopted to stabilize lean air-fuel mixture combustion and conserve fuel through computer control of the air-fuel ratio, and this contributed to superior fuel economy performance.
    *1: Swirl Control Valve
    *2: Integrated Ignition Assembly
    *3: TOYOTA Computer Controlled System
    *4: Light-weight Advanced Super Response Engine


    The 4-speed and 5-speed manual transmissions available for the sedan series were completely updated. The overall length was shortened to accommodate the transverse mounting of the engine due to the conversion to an FF drivetrain. In addition, a 3-speed automatic transmission (which was later replaced by a transmission with a lockup clutch) was available in models equipped with the 2A-LU and 3A-LU engines. Models equipped with the 1C-L engine featured a 3-speed automatic transmission with a lockup clutch that contributed to fuel economy performance. Models equipped with the 4A-ELU engine featured an electronically controlled 4-speed ETC-S automatic transmission. On-board computer was used to control this transmission in response to various road conditions, such as departure from slippery road surfaces and driving on winding roads.

    In February 1984, a 4-speed automatic transmission with a lockup clutch was added to each model equipped with the 2A-LU, 3A-LU and 1C-L engines, and fuel economy performance and quietness were improved by the OD (overdrive) mechanism.


    On the other hand, coupe vehicles equipped with the 3A-U II engine were made available with a 4-speed automatic transmission with a lockup clutch from the time of its initial release. At the time, this was a rare option in the 1.5-liter engine class vehicles and had a great impact. Models with the sporty 4A-GEU engine initially were available only with a 5-speed manual transmission, but later the electronically controlled 4-speed ETC-S automatic transmission was added to the lineup.

  3. Join Date
    Oct 2010
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    877
    #13
    All suspensions for the sedan series were newly designed as a result of the conversion to the FF drivetrain. A MacPherson strut with an L-shaped lower arm was adopted for the front suspension, while a dual link strut with two lower arms was adopted for the rear suspension.

    The suspension for the coupe series adopted the same proven layout of the third generation Corolla, with the front using a MacPherson strut, and the rear using a 4-link coil with a lateral rod. However, the suspension alignment and lateral rod positioning were reviewed to improve driving stability and riding comfort.

    For the steering system, all models of the fifth generation Corolla adopted rack & pinion steering, and the availability of power steering was expanded. However, to accommodate user needs and to expand their choices, a "-less" option (without power steering) was offered to customers not comfortable with power steering.

    The front seats featured fully reclining seatbacks, expanded slide range and finer adjustment pitches to improve comfort and expand the freedom of driving postures. In addition, large fabric headrests were adopted in the sedan. For the rear, the availability of split folding seats was expanded in the sedan to enable various seating arrangements to match usage purposes. Distinctively designed lounge seats — appearing as if they were integrated with the trim — were given to the coupe model.

    Efforts were also made to enhance equipment. Centralized door locks for convenience in getting in and out, intermittent wipers that reduce hassle in rainy weather and an automatic air conditioner to maintain interior comfort were adopted. Other features included power door mirrors, power windows, power sunroof and a multi-use tray.

    Along with the many features and equipment, the expanded interior dimensions of the fifth generation Corolla also contributed to providing comfort. With the adoption of a FF drivetrain, the sedan offered a roomy cabin with expanded head clearance and legroom.

    In an effort to help enhance occupant protection, a crushable body structure was adopted. By allowing a portion of the body to crumple in a rare event of a collision, this revolutionary body structure efficiently absorbed and dispersed the impact load.

    Other Technologies and Equipment
    Bar type digital rev counter designed with consideration of innovation and visibility
    Mud guards to reduce dirt and scratching
    Lights left on notification buzzer to prevent the battery from draining because the driver forgot to turn off the lights
    Auto drive that enables low speed driving without having to press on the accelerator
    Digital quartz clock
    Power remote control door mirrors



    A Corolla beyond Corolla.
    "Higher levels demanded in an era of abundant prosperity."


    In May 1987, the Corolla evolved into its sixth generation model. The catchphrase used in advertisements at that time was: "A new tale in Japanese vehicles has begun. The birth of the all new Corolla, a new grade Toyota sedan." All areas of the new Corolla were completely renovated to go beyond the norms of its class, and the Corolla entered the market armed with a sense of luxury and an even higher level of quality. Because of the rich economy in Japan, the customer needs were greatly changing from satisfaction of ownership to enjoying life and using possession to enhance a personal lifestyle. In designing the sixth generation Corolla, the development team recognized the era had changed from focus on items to focus on things of the heart, and customers sought self fulfillment in their cars as well. To comply with these types of needs, the design team embarked on developments with the idea of providing a vehicle that not merely functioned as a tool or means of transportation but that also provided passengers with "quality time and travel space." As a result, the team successfully achieved interior and exterior designs replete with a sense of luxury that challenged even higher grade vehicles, as well as a high output engine with good fuel economy. The team also searched the range of sensitivity in areas of texture and tone in their pursuit for high levels of quality.

    This sixth generation Corolla was well received by many both in Japan and in overseas markets, and its popularity did not fade. In fact, in March 1989, three years after its release, the sixth generation Corolla set a new record for monthly domestic sales in Japan of 44,000 units. In addition, the wagon and 4WD (four wheel drive) models gathered much attention, which has led to the current RV (Recreational Vehicle) boom in Japan, and achieved the highest monthly worldwide sales of 100,000 units.

    The market in Japan at the time of the sixth generation Corolla development was undergoing a change in its sense of values, shifting from an "era of enhancing items" to an "era of satisfying the heart and mind." With this occurring, the new model had to respond to the change by realizing a high level of quality that greatly exceeded the level sought by vehicles in this class. To achieve this, the development team targeted vehicle development based on a new sense of value that exceeded the boundaries of conventional family cars and compact cars. The team strived to develop a "car that would create new standards for the upcoming decade, the 1990s, as well as a global vehicle that exceeded its class."

    Akihiko Saito, the Development leader, stated, "I believe that the Corolla must erase the image of family cars of the past. Wouldn't it be nice if the quietness and riding comfort of the Crown* and the attractive appearance of the Mark II (Cressida) were achieved in a vehicle the size of the Corolla?" To achieve this concept and development goal, Saito instructed the staff to create a car that provided "high quality time." The main focus of this concept was satisfying the customers by appealing to the five senses. For example, the importance of appearance — a customer will not consider his or her time spent in the car as quality time if the car appears shabby.

    To realize this "global vehicle that exceeded its class" and provides quality time, the team focused on the following:
    1. Provide a lineup of characteristic body styles to best fit the broad lifestyles of the customers.
    2. Achieve a "Fun to Drive" vehicle through outstanding vehicle performance.
    3. Realize high level aesthetic quality for the senses.
    Rather than executing merely a model change, the team focused on these three points and embarked on developments with a spirit of introducing an entirely new vehicle for the market to judge.
    A major feature of the sixth generation Corolla was its engine, which adopted a newly developed double-overhead cam 4-valve mechanism called the "High-Mecha Twin Cam." At that time, while double-overhead cam 4-valve mechanisms enabled high speeds and high output, they were also expensive and primarily mounted in sports cars and sporty models. Use in everyday family cars was not considered. However, the manager of the Engine Development Department declared, "When we pursued the ideal engine with both high performance and good fuel economy, we inevitably turned to this type of engine." With that, the team embarked on the development of a new double-overhead cam 4-valve mechanism for use in a family car — with superior fundamental performance of output and fuel economy, whilst accomplishing excellent mass productivity and low production costs. However, there were many issues that had to be resolved in developments. For example, to determine the optimum cam drive method to open and close the valves, durability tests — lasting several hundred hours at 6000rpm — were repeated over and over using several types of prototype engines. As a result, an engine with high performance and fuel efficiency in the practical application range was completed with characteristics that appeal to the senses with comforting tones.

  4. Join Date
    Oct 2010
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    877
    #14
    In the development of the sixth generation Corolla, a project team was organized to increase overall quality. The team made more than 2,000 proposals and cooperated with more than 100 part manufacturers to improve quality in even areas that the customer would never see. Also, by ensuring high sensory qualities for higher levels of satisfaction, the development staff was confident it had created a new standard for the appearance and finish of Toyota manufactured vehicles. With this level of quality, far beyond the boundaries of conventional family cars, the sixth generation Corolla was well received by many and became a major hit model.
    *CROWN: Introduced in 1955 and is now in its 12th generation as a large luxury passenger vehicle representative of Toyota.

    At the time of its initial release, the sixth generation Corolla was available in four body types, including a 4-door sedan, a 2-door coupe, a 3-door hatchback and a 5-door hatchback. In August 1987, the van and wagon models, which had been carried over from the fourth generation model without any model changes, underwent a conversion to FF (front engine, front wheel drive) drivetrain and joined the sixth generation lineup. When the model change was made for the sixth generation, the 3-door coupe and 5-door models were discontinued in Japan, but a 5-door liftback model was established for Europe.

    Seven types of engines were available at the time of the initial release. This included the 1.3-liter OHC (Over Head Camshaft) 2E engine, the newly developed "High-mecha twin cam" 1.5-liter 5A-F and 5A-FE engines, the 1.6-liter Sports twin cam 4A-GE and Supercharged 4A-GZE engines and the 1.8-liter OHC 1C-II diesel engine. A 1.5-liter OHC 3E engine also was available exclusively for the van model.

    In September 1987, the 1.6-liter High-mecha twin cam 4A-F engine was established exclusively for the 4WD model.

    In May 1989, in the second half of the model period, the 5A-F and 4A-F engines were replaced by the EFI controlled 5A-FE and 4A-FE engines. In addition, the 5A-FHE was established for some grades of the coupe and hatchback models by further tuning the 5A-FE engine for improved output. Then in September of the same year, the 2.0-liter OHC 2C-III diesel engine was added to the lineup for 4WD models.

    For the drivetrain, the front wheel drive was adopted from the time of the initial release for the sedan, coupe and hatchback. In August, three months later, the van and wagon were converted to the FF drivetrain, and the conversion of all Corollas to FF, started on the fifth generation, was completed. Later, Corolla's first full-time 4WD, based on the FF drivetrain, was established to further support the diversification of customer needs.

    A wide and low theme was adopted for all body types, and a luxurious design was given to the sixth generation Corolla. To achieve the exterior design, the Corolla was designed like higher grade vehicles with well-proportioned style, including a large, low form with a small cabin proportion and with rounded lines, which was the newest trend. Specifically, when seen from the side, the exterior design emphasized a carefree image with its straight horizontal lines that seemed to flow from the top of the fender to the rear trunk and with a cabin that appeared to be positioned on top. In addition, a visual effect was also incorporated by bringing the front pillar and rear pillar closer to the center pillar to achieve a well-proportioned style, and a delicately designed radiator grille was adopted to achieve a design that overflows with a sense of luxury.

    As for the interior, the design team began searching for a direction to take the design. To determine that direction, the designers, with the help of the sales staff, visited many customers at their homes to hear opinions. Also, to incorporate the trends of that time, the team even began analyzing songs that were popular at that time (in Japan) to determine what exactly it was that would be accepted by the people. From the analysis of popular songs and from listening to customers first hand, the team was guided in a design direction that led to luxury and freshness. Specifically, the seats adopted a velour, knit fabric and a large, thick design to portray an image of luxuriousness. For the interior color, maroon was adopted — a color which had gained an excellent reputation in use in higher grade vehicles. Creating a new interior space focused on ergonomics. The shape of the meters and the layout and grouping of the controls were designed by carefully examining visibility and operability.

    Of the seven types of engines available at the initial release, the 1.5-liter DOHC (Double Over Head Camshaft)16-valve 5A-F and 5A-FE engines were newly developed to achieve high output, good fuel economy, high response and ample torque characteristics in the practical application range. In addition, the engine sound was carefully tuned to achieve ear-pleasing tones. The characteristic feature of this engine was the "High-mecha twin cam" mechanism created from the concept of "make the ultimate twin cam mechanism a common device." While the conventional DOHC uses a timing belt to drive both camshafts, the lightweight and compact High-mecha twin cam drives one camshaft with a timing belt and the other camshaft with a scissors gear for high intake and exhaust efficiency. As a result, the 5A-F engine achieved a maximum output of 85ps/6000rpm and a maximum torque of 12.5kg-m/3600rpm, and the 5A-FE engine equipped with an EFI achieved a maximum output of 94ps/6000rpm and a maximum torque of 13.1kg-m/4400rpm. The level of confidence that the team had in these engines was apparent from advertisements in Japan that introduced the engines as "Engines that go beyond the boundaries of their class."

    The sporty, 1.6-liter DOHC 4A-series engines included the 4A-GE engine that was refined based on the fifth generation 4A-GELU engine for increased power and the 4A-GZE that was equipped with a supercharger. The 4A-GZE supercharger differed from conventional turbochargers, because it gained its power from the crankshaft, so it had the merit of superior response. In addition, high power and high response in all speed ranges were achieved through various refinements. These included adopting an intercooler and forged pistons, as well as reinforcing the internal structure and components. The 4A-GE engine achieved a maximum output of 120ps/6600rpm and a maximum torque of 14.5kg-m/5200rpm, while the 4A-GZE engine provided a maximum output of 145ps/6400rpm and a maximum torque of 19.0kg-m/4400rpm.

    On the other hand, changes were made to the ignition timing, engine mount and fuel evaporative emission control system for the 1.3-liter OHC 12-valve 2E engine, which featured superior response and good fuel economy, to achieve a maximum output of 73ps/6000rpm and a maximum torque of 10.3kg-m/4000rpm. The 1.8-liter OHC 1C-II diesel engine with high economic efficiency and quietness also was continued from the fifth generation, but the injection nozzle was changed and the injection timing was optimized to comply with Japan's exhaust gas regulations, which were becoming increasingly stricter year by year. The maximum output of this engine was 64ps/4700rpm and the maximum torque was 12.0kg-m/2600rpm. Also, the newly developed, compact, lightweight 1.5-liter OHC 3E engine was adopted in the van model. This engine generated a maximum output of 79ps/6000rpm and a maximum torque of 12.0kg-m/4000rpm and focused on usability in the practical application range.

    In September 1987, the 4A-F engine equipped with the "High-mecha twin cam" was adopted exclusively for 4WD models. This engine was developed based on the fifth generation 4A-ELU engine.

    Then in May 1989, minor changes were made and the 5A-F and 4A-F engines were changed to the 5A-FE and 4A-FE engines with EFI control. In addition, efforts were made to improve the output of some grades of the coupe and hatchback models, and the 5A-FHE engine, which generates a maximum output of 105ps, was adopted. At that time, the 4A-GE, 4A-GZE and 1C-II engines were also overhauled to improve output. Then in September of that year, the 2000cc 2C-III diesel engine was added to the lineup of the 4WD model to meet the needs for a diesel engine with high level startup characteristics in cold regions.

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    #15

    A strut type suspension similar to that of the fifth generation Corolla was given to all four wheels. However, by updating the suspension geometry, shock absorber damping force and component parts, even more superior handling stability and riding comfort were achieved. Also, the TEMS (Toyota Electronic Modulated Suspension), an electronically controlled variable damping force damper, was made available in some of the higher grade models. This system allowed the driver to select the preferred damping force. The system featured an "AUTO Mode," in which the computer adjusted the damping force to either "SOFT" or "HARD" based on the driving conditions, and a "SPORT Mode" for a "HARD" damping force suited for sporty drives.

    For the drivetrain, conversion to an FF design progressed from the fifth generation model, and in August 1987, the van and wagon underwent a full model change to a sixth generation and were converted to FF designs. With this, the entire Corolla series featured an FF design. Then in October of that year, a 4WD model was added that exhibited superior driving performance in various road conditions to meet the needs of various customers. The 4WD system differed with each engine and transmission specifications. In manual transmission models with gasoline engines, full-time 4WD was adopted with a mechanical differential lock, while in automatic transmission models, electronically controlled hydraulic "High-matic" full-time 4WD was established. High-matic full time 4WD detected the throttle opening and vehicle speed and used hydraulic pressure to control the center differential, thus making it easier to take off on slippery roads. This system also did not require any driver control, enabled an easy drive and made the 4WD models more accessible. A full-time 4WD system with viscous coupling center differential was made available for the manual transmission model equipped with a diesel engine in the latter half of the model period.

    In addition to equipping the sixth generation Corolla with features that ensured a comfortable interior environment, the design team pursued comfort that satisfied even the human senses of touch and sound. A good example is that of details in the area of touch. Areas from the meter cluster to the instrument panel and door trim were wrapped with softer materials to achieve a pleasant texture. Meticulous attention was given to even the feel of switches. In the area of sound, penetrating road noise and wind noise were reduced, and engine sound was tuned carefully to create a pleasant tone. In addition, computer analysis was used to achieve a body structure that generated minimum noise and vibration, and, as a result, a superior level of quietness was achieved. On the other hand, in the area of air conditioning, efforts were made to improve dynamic pressure ventilation performance, which played essential roles in maintaining the cabin air fresh.

    Efforts were also made to enhance comfort and convenience equipment. The seats were available with a seat lifter, lumbar support, side support and full-flat reclining. Rear seat types were available according to the body type and grade, including a 60:40 split retractable rear seat and a one-piece fixed rear seat. In addition, a countless number of comfort and convenience equipment was available, such as centralized power windows switches, an air conditioning system that enabled rapid heating and cooling, sun visors with vanity mirrors, a power moonroof, 7-step adjustable tilt steering and a rear window defogger with heater wires.

    Numerous easy-to-use storage spaces were also provided, including large door pockets, a front console tray, a glove box under tray, a console box with a cassette box and a front seatback pocket. The van model was designed with a lower floor when converted to an FF design, and a class top level cargo area was ensured.
    To accommodate the enhanced engine performance and drive power, disc brakes were adopted for the front brakes on all models, ensuring optimum braking force. In addition, a brake booster, that enabled a large braking force to be generated with only a light pedal pressure, and X-type dual circuits to handle the rare event of brake abnormalities were adopted. For models with sporty engines, ventilated disc brakes with superior anti-fade performance were adopted to ensure high braking force.

    In terms of body rigidity, high levels were achieved by optimizing the frame structure and profile shape of the components. In addition, adjustable seatbelt anchors were adopted to ensure a comfortable fit by passenger of any physique.
    Other Technologies and Equipment
    Advanced panoramic digital meters with superior visibility
    Power adjustable and retracting outer mirrors
    Glare proof inner mirror that prevents glare from the lights of trailing vehicles
    Push button heater control panel and push button hazard lamp switch with superior operability
    Trunk room lamp
    Cup holders
    Fabric toned trunk mat
    Electronically controlled carburetor with a fuel cut off function to contribute to fuel economy performance
    Turnover type clutch pedal with reduced operation force



    High-end, impressive Corolla.
    "Shifting Corolla value to the range of emotions and sensitivity."

    The seventh generation Corolla was developed by carefully pursuing the fundamental performances of driving, turning and stopping, and dramatic improvements were made to every aspect. This seventh generation Corolla debuted in June 1991 with the catchphrase "Big and Safety." However, in 1991, the booming economy of Japan began to take a downward turn, and this impacted new car sales throughout the country. The seventh generation, which had been developed as a masterpiece, was no exception, and, unfortunately, the sales volume in Japan did not grow as had been expected. Needs of the public also began to change as focus shifted to quality as well as price. The seventh generation Corolla boasted a high level of completeness and was replete with abundant equipment that appealed to the consumer. However, the design team became keenly aware of the importance of having a correct understanding of the times and customer needs. Despite these backgrounds, a production volume of 2.4 million units was recorded, and the top market share in its class was steadily maintained. In fact, many seventh generation Corollas can still be seen on the road as it has maintained its image as a good car, and it still is treasured by many even today.

    The economy of Japan at that time had enjoyed continued abundance, and the value sought in vehicles had diversified. This in turn led to a further increase in customers with preferences for higher grade vehicles. With these conditions, the sixth generation Corolla was a big hit with its higher level quality that surpassed the boundaries of family cars. Planning and development of the seventh generation Corolla was started based on a concept of keeping with the previous model and not being caught in the boundaries of family cars.

    Generations of Corollas had secured its role as a family car that had led Japan's motorization. By this time, the Corolla series had become the worldwide leader of family cars. With this in mind, the design team wanted the seventh generation Corolla to once again be cutting edge. The basic concept was to create the next generation standard. Under this concept, Development leader Akihiko Saito analyzed the needs of the new generation. With the values of the public changing from pursuing material abundance to fulfilling the heart and mind, Saito realized the upcoming generation would value a product that deeply inspired the soul of the customers. Saito came up with the keyword "deep impression" and emphasized: "The impression that a car makes is first developed when the essential functions and performance significantly exceed expectations." With this basic idea in mind, the team carefully pursued fundamental vehicle performances, including driving, turning and stopping.

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    #16
    Development of the seventh generation Corolla centered around three specific themes. First, create style that overflows with beauty and amenity space that is gentle on the passengers. Second, further evolve fundamental driving performance. Finally, pursue thorough safety and reliability for a sense of security that satisfies the soul. Saito did not focus on merely increasing the levels of these areas, but rather believed that dramatic improvements in a new dimension would lead to the creation of a next generation standard.

    In order to enhance all aspects of driving, turning and stopping, all development departments, such as the engine and suspension departments, were integrated. This team stayed at a test course in Shibetsu City in Hokkaido for a total of six months, where they faced the challenge of taking the vehicle's fundamental performance to a new dimension. The test course in Shibetsu was selected, because it had winding curves like that of everyday European roads, and the team could emulate the authentic ride of European-manufactured vehicles. Exhaustive testing and discussions were held to the point that, later, the team referred to this period of development as the "Shibetsu Training Camp." There, the defensive barriers between each department were cleared away, opinions were contributed even by those without direct responsibility, and the team worked diligently to create a new level of quality.

    Development leader Saito expressed his aspirations when developments first began, "Create a vehicle that customers can select with confidence, rather than a vehicle that customers can tolerate." The seventh generation Corolla — which expressed a high level of completeness and quality suited for the next-generation standard — achieved maturation that deeply impressed the customers. In addition to the high quality finish of the interior that surpassed that of higher grade vehicles, the elaborately finished exterior was accepted by all age groups and exhibited the height of Toyota's technical strength.

    Two types of body variations were available when the seventh generation model initially was released, including the sedan and 2-door coupe (Corolla Levin), and later the wagon and van were added to the lineup. The following year, the 3-door hatchback (Corolla FX) and the 4-door hard top (Corolla Celles) were added simultaneously for a final total of six body variations.

    Gasoline engines were available in five types including the 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE, the Sports twin cam 4A-GE and the supercharged 4A-GZE. For the diesel engine, the 2.0-liter 2C was adopted, for a total of six engine types.

    The design of the seventh generation focused on an image with an abundance of curves. Body panels were deeply drawn toward the body ends, giving this model a rich body design that expressed a high class family sedan style with the image of luxury and driving performance. While emphasizing high quality, many characteristic traits of the Corolla were retained as well. Notable features included large irregularly shaped headlamps, horizontal radiator grille and integrated front bumper designed for maximum cooling performance and aerodynamics. The interior, as well, took on a curved theme and achieved a dramatic increase in the level of design and material quality. The instrument panel was configured from smoothly curved lines, and four round meters with good visibility were adopted. The safety pad in particular was designed with a large, integrated form with minimal gaps and parting lines, further enhancing the high quality image.

    All gasoline engines of the seventh generation Corolla were designed as EFI-equipped (Electric Fuel Injection) double overhead cam engines. These EFI and twin cam engines were called second generation "High-mecha twin cam" engines. Notable characteristics included the designed head cover, surge tank and hydraulic engine mounts adopted on all vehicles to contribute to superior NV (noise and vibration) performance.

    The 1.3-liter 4E-FE engine was developed based on the conventional 2E engine, converted to EFI and "High-mecha twin cam" configuration with increased displacement. This engine generated a maximum output of 100ps/6600rpm and a maximum torque of 11.8kg-m/5200rpm.

    The 1.5-liter 5A-FE engine — inherited from the sixth generation — incorporated new designs in various areas around the cylinder head, and a maximum output of 105ps/6000rpm and a maximum torque of 13.8kg-m/4800rpm were generated. By optimizing the intake port shape in particular, an air swirl was generated inside the combustion chamber for efficient combustion, and high output was achieved. In addition, a knock control was incorporated in the engine control system to suppress knocking and to achieve optimal ignition timing and combustion at all times. Furthermore, torque control was adopted in automatic transmission models to reduce the shift shock that occurs when changing gears, and an engine profile with mild, easy to handle output and torque was achieved.

    The 1.6-liter 4A-FE engine adopted a dual exhaust manifold to improve performance and generated a maximum output of 115ps/6000rpm and a maximum torque of 15.0kg-m/4800rpm. The Sports twin cam 4A-GE with the same 1.6-liter displacement underwent modifications to the extent that it could be called a newly designed engine. Output improvements were targeted, and the intake volume was increased by adopting a 5-valve design with three intake valves and two exhaust valves per cylinder. In addition, agile response like that of a sports engine was achieved using four independent throttle valves — one for each cylinder. Also, a Variable Valve Timing (VVT) system was adopted for the intake side camshaft to supplement low and medium speed torque, and a maximum output of 160ps/7400rpm and a maximum torque of 16.5kg-m/5200rpm were generated, realizing a sporty engine beyond that of the past. No major changes in particular were made to the supercharged 4A-GZE engine that was continued from the sixth generation Corolla, but minor changes were made to the exhaust system, and a maximum output of 170ps/6400rpm and a maximum torque of 21.0kg-m/4400rpm were achieved.

    For the diesel engine, the 2.0-liter 2C-III diesel engine was adopted. This was the engine available on the 4WD (four wheel drive) models of the sixth generation. For the seventh generation Corolla, this diesel engine was optimized for use in FF (front engine, front wheel drive) vehicles by altering the valve timing and the shape of the exhaust manifold. A maximum output of 73ps/4700rpm and a maximum torque of 13.5kg-m/2800rpm were achieved.

    The transmission basically followed that of the sixth generation Corolla. Priority was focused on the shift feeling for manual transmissions, and subtle changes were made to the unit and its operating system. These changes included adopting a triple-cone synchromesh, adding a shift wire moderation adjustment mechanism and making changes to the shift knob. The daring adoption of a heavier shift lever with mass damper — a first for Toyota — led to minimal vibration and a good shift feeling. In automatic transmissions, the newly developed Super flow torque converter was adopted to achieve powerful departure and acceleration performance and to significantly improve fuel efficiency.

    Similar to the sixth generation Corolla, a 4-wheel strut suspension was adopted with L-type lower arms in the front and dual-link arms for the rear. The component parts and characteristics were reviewed, and superior handling stability was ensured. In addition, the TEMS (Toyota Electronic Modulated Suspension) was adopted in higher grade models. For enhanced comfort, the former 2-step setting of "SOFT" and "HARD" was upgraded with the addition of a third step, "MEDIUM," making possible a finer adjustment of damping characteristics.

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    #17
    Separate from these suspensions, a newly developed Super-strut suspension was made available for the Coupe (Levin) and 3-door hatchback (FX). This suspension, which provided high cornering performance comparable to a double wishbone configuration, supplemented the weaknesses of the conventional MacPherson strut suspension and minimized extreme wheel alignment changes by suppressing the tilt of the tires when cornering. Also, unstable vibration and torque steer, which had been the weak point of front wheel drive vehicles with high output engines, were reduced. This allowed the tires to exhibit their full potential, and, as a result, overall cornering performance was significantly enhanced.

    For the steering mechanism, rack & pinion steering similar to that of the sixth generation Corolla was adopted. Two types of steering mechanisms were available in the seventh generation Corolla, including the proven engine speed sensitive power steering and the newly-adopted New Progressive Power Steering. The newly-adopted steering system controlled the firmness of the steering wheel according to vehicle speed and road surface reaction force. This enabled easy operation at low speeds, which was light enough to be turned with one finger, and a firm and stable steering feel at high speeds.

    In the development of the seventh generation Corolla, the team pressed onward with efforts to increase quality beyond the boundaries of family cars — a task set forth by the sixth generation — and paid close attention to every detail. For the interior space, comfortable seating space was achieved by primarily expanding the head clearance, rear legroom and interior width. To improve comfort in the rear seat in particular, the arrangement of the seat rails of the front seat was reviewed, and the rear seat leg space was expanded. The switches were completely redesigned and converted to switches that are easy to operate with an improved operation feeling. In higher grade models, automatic air conditioning was adopted as standard equipment. Other deluxe equipment was prepared, including vehicle speed sensitive door locks, automatic headlamps, a clearance sonar that detected obstacles and urged caution to the driver and a wireless key-less entry system. As a result, an increase in quality was achieved that went beyond expectations and significantly exceeded the boundaries of family cars.

    [IMG]Various safety devices were made available in the seventh generation Corolla to accommodate the customers' increased consciousness toward safety. Equipment was enhanced in line with that of present day vehicles. The 4-wheel Anti-lock Brake System (ABS) used to suppress tires from locking during sudden braking, and the high mount stop lamp, which increased visibility for trailing vehicles, were made available as options on all models. In addition, a computer analyzed collision safety body structure, driver's seat SRS (Supplemental Restraint System) airbags and side door beams were adopted. Furthermore, safety performance also was considered from a hardware aspect and efforts were made to ensure braking force. This included adopting ventilated front disc brakes in all vehicles, and, in some models, large diameter disc rotors and opposed piston brake calipers. Other Technologies and Equipment Viscous LSD (Limited Slip Differential) Electric combination meters Seats made by Recaro 3-point seatbelts for the rear seat Projector fog lamps Flame retardant treatment of interior parts


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    #18

    Pursuing the intrinsic economic efficiency of family cars.
    "Concern for environmental problems and safety. One answer to the radically changing era."

    The eighth generation Corolla appeared on the market in May 1995 during a time when Japan was facing a sluggish economy, and strong considerations were being sought for the environment and economic efficiency. The Corolla — which with every generation had been developed as the best compact car for balancing harmony with the society and its members — was developed this time with just the right size and a high level of quality. First, the team targeted harmonization with society and pursued economic efficiency (resource conservation), environmental performance and safety. As a result, a high rigidity body and top level fuel efficiency were achieved through significant weight reductions. Safety performance also was maintained firmly by enhancing safety equipment. Careful consideration was given to environmental aspects, including improving recyclability and achieving even cleaner emissions from the diesel engine.

    This eighth generation Corolla held firmly to Corolla's number one position in domestic sales, which had continued since 1969, in part, because of the enthusiasm of the sales staff and the popularity of the wagon.

    The era of Japan's booming economy, which had continued for many years, came to an end; with this, rapid changes began to occur in the social environment and preferences for luxury items shifted to an era that sought simple yet sturdy goods. A greater awareness of environmental issues was developed, and consumers demanded that goods be manufactured with consideration of the global environment and in harmony with the society. In the midst of these changes, developments of the eighth generation Corolla began.

    Development leader Takayasu Honda stated the following concerning developments of the eighth generation Corolla: "Wanting to maintain the status of 'the best' compact car, I believed that in addition to polishing its appearance and driving performance, our first thoughts should be of harmonization with society, because the Corolla is the most sold car globally. I believed that we could answer the needs for a socially responsible car by focusing on safety and environmental measures." The development theme based on this idea was "a slim, healthy car." In other words, Honda's challenge was to lose the fat, develop the muscles and create a well toned, healthy car.

    The team's first focus — from the viewpoint of resource conservation and energy savings — was on making significant weight reductions and improvements in fuel efficiency. However, a critical development point also was to maintain collision safety performance, which could easily lead to an increase in weight. To solve these contradicting issues, the team began conversing with the Manufacturing departments from the initial development stage and obtained opinions on an ideal body structure. Then the team used computer analysis to optimize the structure and widely adopted high tensile steel sheet metal. As a result, a high rigidity body was realized with up to 50kg weight reduction for the sedan and 70kg for the coupe — and good fuel efficiency was achieved.

    Another major focus in the development of the eighth generation Corolla, a reflection of the times, was the concern for the total cost of ownership. This concept was established in an effort to reduce the total cost that pertained to vehicle ownership, including the initial vehicle price and maintenance costs. After ensuring safety and environmental performance, the team thoroughly pursued total cost reductions by improving the engine's fuel economy and reducing the weight of the body. In addition, the team considered ways to curb repair costs should the vehicle become damaged and adopted a horizontally partitioning structure for the front bumper.

    The Corolla was created in 1966 as a vehicle to clear the way for motorization in Japan and has become well loved throughout the world. As stated by Development leader, Takayasu Honda, the eighth generation Corolla was released to the world in May 1995 as a car that transcended generations and nationalities.

    At the time of its initial release, the eighth generation Corolla was available in five different body types, including a 4-door sedan, a 2-door coupe and the van from the previous model, as well as a wagon and a hardtop (Corolla Celles), which had both undergone a minor model change. Later in January 1997, the MPV (known as the Corolla Spacio in Japan and New Zealand, and as the Corolla Verso in Europe) was added to the lineup as a new body type. The MPV in particular gained a favorable reputation for its diverse seat arrangements made possible with three (or two, depending on the country) rows of seats.

    A total of five engine variations were available, including four gasoline engines and the 2.0-liter OHC (Over Head Camshaft) 2C-III diesel engine. The gasoline engines included the 1.3-liter 4E-FE, the 1.5-liter "High-mecha twin cam" 5A-FE and the 1.6-liter 4A-FE and 4A-GE engines. In August 1998, in the latter half of the model period, the 2C-III diesel engine was replaced by the 2.2-liter 3C-E engine.

    The eighth generation Corolla was designed newly with a clean-cut taste, with a roomy cabin that was easy to get in and out of and with body panels utilizing simple, solid surfaces. With this model, the team pursued a well-balanced sedan design that would stay fresh for many years. While exploring new design tastes, the designers also pursued a design that contributed to excellent visibility and operability. Specifically, considerations were made for easy recognition of the front end and corner areas from the driver seat by providing an energetic hood relief that extended from the hood area to the headlamps. Likewise in the rear, superior functional beauty and a sense of high quality was also achieved with the rear combination lamps that emphasized a clean image, the lowered rear glass frame for better visibility in the rear direction, the ducktail shaped trunk lid and the lowered trunk opening height for ease of loading and unloading cargo.

    The theme of the interior design was clean and comfortable, and with this theme, the design team pursued clear, refreshing taste with a high level of quality. Ample seating space was ensured while maintaining just the right size for a compact car, and a compact design with good visibility was realized without any sense of being cramped. The new model also featured superior usability, including controls that were easily within reach from a natural seating posture. Specifically, the overall interior width and height were expanded, and the front head clearance was enlarged upward, forward and sideways to further increase the sense of liberation. The instrument panel took on a generous, simple, horizontal design, and its height was lowered to reduce any sense of constriction on the passengers. Also, the center cluster, which in the past had been divided into three sections, was integrated for a more refreshed impression. Moreover, a luxurious image was expressed by adopting three-dimensionally designed door trim with integrated armrests and pockets.

    All 5 types of engines available at the time of the new model's initial release were carried over from the seventh generation. These engines included the "High-mecha twin cam" 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE and the Sports twin cam 1.6-liter 4A-GE gasoline engines and the 2.0-liter 2C-III diesel engine. However, the high efficiency oriented "High-mecha twin cam" engine, the Sports twin cam engine for sporty driving and the High-torque diesel engine designed for good fuel economy were all significantly tweaked for better performance while perfecting the unique qualities of each engine.

    For the 5A-FE and 4E-FE, the prime engines of the Corolla, the team strived to achieve noticeable improvements in performance, while keeping in mind economic efficiency and operational ease. Targeted refinements included the increase of torque in the practical application range and achieving even better fuel efficiency. To realize this, a broad array of changes were made, such as adopting an Idle Speed Control (ISC) device, expanding the fuel cut off range when decelerating, reducing friction and making changes in the intake and exhaust systems. As a result, the 5A-FE engine generated a maximum output of 100ps/5600rpm and a maximum torque of 14.0kg-m/4400rpm, and the 4E-FE engine achieved a maximum output of 88ps/5600rpm and a maximum torque of 11.8kg-m/4600rpm. The lowered maximum output of these two engines compared to the seventh generation model became a major topic of conversation at that time. This was the result of preference for stress-free operational ease in daily use rather than peak power in the high speed range. However, lowering output figures generally had not been done before other than when emissions regulations were tightened or when engine output measurement methods were changed.

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    #19
    On the other hand, for the Sports twin cam 4A-GE engine, the team targeted a higher output in the high speed range, suited for sporty driving and smooth power delivery through the entire speed range. Advanced technology from the former model was inherited, including the 5-valve mechanism, the VVT (Variable Valve Timing) mechanism and independent throttle valves for each cylinder. Changes were made to the valve operating system, intake and exhaust systems and combustion chamber to achieve a high revving, high output engine with a maximum output of 165ps/7800rpm and a maximum torque of 16.5kg-m/5600rpm. Also, a single muffler with a built-in variable valve was adopted in place of the conventional dual muffler. With this muffler, appearance from the rear of the vehicle was enhanced, and higher performance was achieved together with a lower noise level.


    The injection pump characteristics were changed for the 2C-III diesel engine to comply with stricter domestic emissions regulations, and the emissions volume of black smoke and NOx (nitrogen oxide) was reduced to achieve an even cleaner engine. However, no changes were made to the maximum output and maximum torque, which remained at 73ps/4700rpm and 13.2kg-m/2800rpm respectively. The 1.6-liter 4A-FE underwent further reductions in weight, but the output figures remained unchanged at a maximum output of 115ps/6000rpm and a maximum torque of 15.0kg-m/4800rpm.
    Transmissions also were carried over from the seventh generation model. Manual transmission was available in either a 4-speed or 5-speed version, while the automatic transmission was available in a 3-speed, 4-speed or a 4-speed with ECT-S. Resin parts were also adopted for a more lightweight design, and the shift stroke of the manual transmission was shortened for an improved shift feeling. The component parts of the automatic transmission were reviewed for a better match with the engine characteristics, and changes were made to the hydraulic characteristics to achieve smooth departure acceleration and response.

    As in the past, a MacPherson strut suspension with an L-type lower arm was adopted for the front, and a dual-link type MacPherson strut suspension was adopted for the rear. Stress analysis using advanced technology was done on each component part to achieve optimized characteristics and significant weight reductions. As a result, high level handling performance and driving stability were achieved and unpleasant vibration (harshness) and noise were reduced. In addition, the gear ratio and hydraulic properties of the power steering system were changed to achieve a smoother steering feel.

    In 4A-GE engine models equipped with a Super-strut suspension, a torque sensitive helical LSD (Limited Slip Differential), suited for sporty driving, was adopted for the first time in Japan on an front wheel drive vehicle. With this setup, if the inside wheels starts spinning while cornering, optimum driving force is immediately delivered to the outside wheels to achieve stable cornering and excellent controllability.

    Developments of the eighth generation Corolla progressed with priority on improving seating comfort while maintaining just the right size for a compact car. The front seats were developed with the idea of achieving comfortable seats that do not cause fatigue even on long drives. The support and fit of the seats were improved and secure seating comfort was achieved by optimizing the shape of the seatbacks and seat cushions. The seatbacks were designed with a contour close to the shape of the human body for maximum support and even pressure distribution. The cushions provided a mild seating comfort and improved vibration absorption with high elasticity, high density urethane foam. On the function aspect, the reclining adjustment allowance of the driver's seat was expanded, and the level of freedom in driving posture was widened. For the rear seat, the volume at the top of the seatback and the thickness of the seat cushion pads were increased to improve support and fit, and a stable seating posture was achieved. In the sporty grade models, high-support sports seats manufactured by Recaro were made available as an option.


    In the equipment area, the team also meticulously pursued comfort and convenience. Features included a tilt and slide power moonroof that provided interior ventilation and a liberating feeling, a wireless door lock remote control system, a 6-speaker Corolla live sound system and map lamps with a room lamp function. A wide array of storage spaces were also provided, including a large capacity glove box, a gadget case in the lower panel of the driver's seat and pull-out type cup holders. The height of the luggage opening also was lowered to make loading and unloading of cargo easier. A superior level of quietness, which greatly impacts interior comfort, also was achieved by analyzing vibration and noise properties through computer simulation and through repeated evaluations in an actual vehicle. In addition to reducing vibration transmission to the body, sound insulating and sound absorbing materials were optimally positioned to reduce vibration and noise, and differences in surface levels of exterior body parts were reduced to achieve a flush surface design, reducing wind noise as well.

    The design team thoroughly pursued measures for preventive safety to stop an accident before it occurs and measures for collision safety to minimize damage should an accident occur.

    For preventive safety, an exterior design with easily recognizable front and rear overhangs, easy to operate meters and switches with excellent visibility and seats that do not cause fatigue even on long drives were adopted. These features maintained a comfortable environment for the driver to implement optimum driving maneuvers at all times. In addition, ABS (antilock breaking system) to suppress tire lockup during sudden braking, high mount stop lamps to increase visibility for trailing vehicles and a rear spoiler with a built-in LED stop lamp were available.

    In the area of collision safety performance, a body structure that efficiently absorbs impact energy during a front or rear end collision, side door beams that suppress deformation when a side collision occurs and energy absorption materials were adopted to help minimize damage to the cabin. Other safety features included a new impact absorption steering column, SRS (Supplemental Restraint System) airbags and 3-point ELR (Emergency Locking Retractor) seatbelts. As a result of thoroughly pursuing safety performance in this way, passenger protection performance was achieved that cleared both the safety standards in Japan and the side impact standards of the United States — the strictest standards in the world.

    On the other hand, the team also dealt aggressively with energy conservation, resource conservation and nature protection. The eighth generation Corolla contributed to suppressing global warming by adopting a lightweight body structure and optimizing engine control, which enhanced fuel efficiency and reduced CO2 (carbon dioxide) emissions. From the viewpoint of efficiently utilizing resources, TSOP (Toyota Super Olefin Polymer), a material that excels in recyclability, was adopted in the bumper and cowl louver, and recyclable material was used in the luggage trim and floor carpet. In addition, numerous environmental protection measures were implemented, such as adopting a horizontally partitioning front bumper structure designed for easier repair, reducing the amount of resin and rubber used, stamping material symbol designations on the primary components and adopting a new refrigerant for the air conditioning unit.

    Other Technologies and Equipment
    Semi concealed wipers to improve visual quality and reduce wind noise
    Ignition key illumination for improved nighttime use
    Wood grained center cluster for a sense of luxury
    One-push power window and power door lock switches centralized in the armrest of the driver's seat
    Luggage mat integrated with the spare tire board to prevent mat slippage
    AT shift position indicator integrated in the meters
    Radio antenna embedded in the rear window glass
    Rear seat center armrest
    Buzzer to prevent driver from forgetting the keys

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    #20


    Start from scratch in the creation of new value.
    "Break the link with the past and target a global standard for the 21st century."

    In 2000, new car sales in Japan were continuing to fall due to the continued sluggish economy, and each automotive manufacturer faced concerns about the inability to sell their cars. In the midst of these conditions, the ninth generation Corolla was born and marketed with the catchphrase "New Century Value." Development leader Takeshi Yoshida challenged the development team with a theme of "start from scratch." With this theme, developments proceeded by daringly breaking away from the can't fai" image of the Corolla, which had been fostered to become a worldwide brand, as the team accepted the challenge to create new value for the upcoming 21st century.

    The major characteristics of the ninth generation Corolla included interior comfort and high level quality and finish that rivaled that of higher grade vehicles, as well as ease of use and reliability. To begin developments, the team first wiped away the basic concept of the existing "Corolla" and completely redesigned all areas beginning with the platform. Innovative approaches were adopted in all aspects, including incorporating a European exterior design plan for the first time. The result was a Corolla that transcended all other Corollas with high comprehensive performance and superior total balance. With this, the Corolla brand was reborn as a worldwide strategic vehicle suited for the 21st century standards with sufficient family car features. Competition in Japan intensified due to the impact of the economic climate and the emergence of tough competitors. However, the Corolla's world market share, including market share in Europe, the United States and Asia, continued to increase. In 2005, 1.39 million Corollas were sold worldwide, further reaffirming the brilliance of the Corolla as a global car.

    In 1997, the year that Takeshi Yoshida embarked on the development of the ninth generation Corolla, the popularity of the sedan began to diminish in the domestic market with the emergence of the minivan. It also became apparent that the class of consumers purchasing Corollas was getting older. To Yoshida, this reflected a loss in brand brilliance that had been enjoyed in the past.

    During the development of the ninth generation, the drop in brand strength had reached such a serious state in the domestic market that the team even examined the possibility of changing the Corolla name. However, Yoshida did not approve of this proposal. His reason for not approving the change was that when he was involved in the development of the Soluna, a local production model developed as a strategic vehicle for Asia, he learned firsthand the Corolla was a historical brand fostered to the point that it had gained a favorable reputation worldwide. Thus, based on personal experience, Yoshida insisted that the name remain the same. As a result, the vehicle name Corolla continues to be used even today.

    Although Yoshida elected not to change the name, he recognized that the car itself needed a huge change. Yoshida expounded on the mindset of that time: "I constantly heard about how the Corolla was a 'can't fail' vehicle for Toyota. However, I believed that if a manufacturer is overly concerned about failure and ultimately places priority on cost and production ease, that manufacturer will end up making a product that is convenient for themselves. I pondered a great deal about how I could change this mindset." With this, Yoshida emphasized the need to "start from scratch" — to break away from the ordinary concept of the class, target high standards in a wide range of arrays, including design, performance and quality, and even forget about the trademark name.

    From the initial stages of development, a technique referred to as "Large Room Developments" was introduced to encourage cooperation between each department. With this technique, the development staff, representatives from the production plants, members of the Design department and cooperative manufacturers gathered together in one room and proceeded with the tasks at hand. As a result, the intentions of each department were smoothly communicated, and each department and group assumed responsibility as the team pursued the same goal — "creation of a global standard for the 21st century."

    Three major items were targeted in the development of the ninth generation. First, packaging, style and quality that broke away from the conventional concept for this class. Yoshida believed that convenience was an obvious necessity for the 21st century, and performance and quality that responded to the senses, such as comfort and beauty, would be highly regarded. The second area of priority was an authentic ride that can be enjoyed by all. To enable everyone to enjoy a high quality drive that responds to the senses, the newest technology was generously introduced and no compromises were made in the area of fundamental vehicle performance. Finally, the third priority area was safety and environmental performance demanded by the new century. For this area, the team aggressively tackled the necessities for safety and the environment that would be expected in future cars.

    The Corolla was the constant pushing force for motorization in Japan. In overseas markets, the Corolla had become a hallmark for quality, customer satisfaction and value for money provided by Japan-made products. With this history, in addition to complying with the needs of the ripened market in Japan, satisfying needs in overseas markets had become a theme that could not be set aside. As developments progressed and as the team searched for a "21st century global standard," Yoshida became aware of the Corolla's origin. Each successive Corolla had always been a product that did not betray the needs of the era. This included quality, ease of use and high versatility that allowed the car to be driven anywhere. Providing the customer with this type of reassurance was an incredibly important role of the Corolla as a global family car. Another element that could not be set aside with the Corolla was enabling even more people to experience its quality and gain a high degree of satisfaction.

    At the end of June 2006, the total number of Corollas produced exceeded 31.6 million units, giving the Corolla the record for the greatest number of vehicles produced and sold worldwide. Thus, the "DNA" of the Corolla will continue to be inherited in the future as new history is engraved.

    The release of the ninth generation Corolla began with two body variations, including the sedan and wagon (Fielder), and with the release, the coupe model (Levin) was discontinued. Later, a 5-door hatchback (RunX) was added to the lineup, and a 3-door hatchback model was also made available for the overseas market. Also, continuing from the previous generation, the minivan type Multi Purpose Vehicle (Spacio, Corolla Verso in Europe) with 3-row seats was added to the ninth generation lineup. In Japan and in the U.S., a light cross country model (Voltz / Matrix) was released as a derivative model, bringing the total number of body type variations to six.

    Engine variations were renovated, and all gasoline engines were a part of the "New Generation BEAMS (Breakthrough Engine with Advanced Mechanism System) Engine-series" and adopted the VVT-i (Variable Valve Timing-intelligent) system. Four types of gasoline engines were available, including the 1.3-liter 2NZ-FE, the 1.5-liter 1NZ-FE, the 1.8-liter 1ZZ-FE and the new 2ZZ-GE sports engine. For the diesel engine, the 2.2-liter 3C-E engine was continued from the eighth generation, bringing the total number of engine types to five. In addition, the 1.4-liter 4ZZ-FE and 1.6-liter 3ZZ-FE gasoline engines, and the 1.4-liter 1ND-TV and 2.0-liter 1CD-FTV diesel engines were made available for the overseas markets.

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Toyota Corolla Heritage